Portable, self-contained, evaporative air cooler

ABSTRACT

A portable, self-contained, evaporative air cooler. An elongated, vertically oriented cylindrical canister has a lower end containing a watertight basin. A fan assembly has a downwardly directed air inlet port and a horizontally directed air exhaust duct. The fan assembly drops into and rests upon, an open, upper end of the canister. A cutout in the upper sidewall of the canister accommodates the air exhaust duct. At least one air inlet is provided in the median portion of the canister sidewall, between the upper and lower ends. An evaporative air filter, elongated and cylindrical in configuration, is attached to and extends downwardly from the air inlet port. A water pump located in the basin includes a water distribution system, delivering water to the upper edge of the air filter. Air, passing through the saturated air filter, is cooled and humidified, before being discharged through the exhaust duct.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to the field of evaporative coolers, particularly those which are portable. More particularly, the invention pertains to a high output, compact, evaporative room air cooler, including a vertically oriented cylindrical canister containing a cylindrical evaporative air filter and supporting a centrifugal fan assembly.

2. Description of the Prior Art

U.S. Pat. No. 2,557,276, issued to Gerow, shows a Portable Evaporative Cooler including a motor having upper and lower shafts with a common axis. The lower shaft drives a water pump and the upper shaft powers an axial flow air fan. A porous filter is saturated with water, and air drawn in through the filter is exhausted upwardly and outwardly by the fan.

In U.S. Pat. No. 4,615,182, granted to Worthington, also shows an axial flow air fan having a variable speed feature. The fan is used in conjunction with a planar, air permeable pad, over which water is distributed by pump assembly running independently from the fan speed controller.

A Portable Cooling Mechanism is disclosed in U.S. Pat. No. 6,915,654, granted to Johnson. This arrangement also relies upon an axial flow air fan, and a cooling media in the shape of a planar disc through which air passes. A circular water spray bar is used to wet the cooling media.

A Portable Heating And Evaporative Cooling Apparatus is shown in U.S. Patent Application Publication US 2003/0131985, filed by Patterson, et al. Different attachments are placed over the output port of a blower, depending upon whether heating or cooling is desired. In the cooling mode, evaporative cooling media within the evaporative cooler frame, are saturated with water provided by a reservoir and a sump pump.

In U.S. Pat. No. 4,428,8090, issued to Harrell, a Cylindrical Evaporative Cooler Apparatus is illustrated. Harrell employs a cylindrical pad frame provided with an integral trough through which water is delivered to evaporative pads held by the pad frame. Apparently designed for a roof-top mount, Harrell's cooling apparatus delivers its humidified and cooled air vertically and downwardly.

SUMMARY OF THE INVENTION

The portable, self-contained, evaporative air cooler of the present invention comprises an elongated, vertically oriented, cylindrical canister. The canister has a lower end, an upper end, and a median portion extending between the lower and upper ends. The lower end of the canister includes a watertight basin, for storing a supply of water. The upper end of the canister has an open top and includes an exhaust duct cutout. The median portion of the canister includes at least one air inlet.

The cooler also includes a cooler sub-assembly comprising a fan assembly and an evaporative air filter. The fan assembly includes a fan housing, a fan motor having a rotary output shaft, and a fan impeller attached to the motor's output shaft. The fan motor and the fan impeller are located within the fan housing. The fan housing includes a lower air inlet port adjacent the air suction side of the fan impeller, and an air exhaust duct adjacent the air output side of the impeller. The air inlet port is located within and surrounded by said open top, and a portion of the exhaust duct fits within the exhaust duct cutout in the canister. The remaining portion of the exhaust duct extends to the exterior of the canister, for output of the cooled and humidified air.

The evaporative air filter is elongated and cylindrical in configuration. It is preferably constructed from an air permeable element in combination with a foraminous support frame, generally right-circular cylindrical in configuration. The evaporative air filter has its upper end attached to the air inlet port of the fan housing, and extends vertically and downwardly from the air inlet port interiorly into the main body of the canister.

The cooler sub-assembly also includes a water pump, preferably located in the watertight basin in the lower end of the canister. A water distribution system accepts the water outputted from the water pump, and delivers water around the upper end of the evaporative air filter.

The suction provided by the fan assembly draws warm and dry air horizontally into the canister through the air inlet. Upon passing through the water-saturated evaporative air filter, the air is cooled and humidified. This cooled air then passes upwardly and vertically through the interior of the air filter, into the fan assembly. There, passing through the centrifugal fan, the cooled air is redirected to exit horizontally through the air exhaust duct.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side perspective view of the portable, self-contained evaporative cooler, showing the side air inlet grills and the air exhaust duct;

FIG. 2 is an exploded, front perspective view, showing the cooler sub-assembly vertically removed from the elongated cylindrical canister;

FIG. 3 is a transverse, cross-sectional view, taken on the line 3-3, shown in FIG. 1;

FIG. 4 is a longitudinal, cross-sectional view, taken on the line 4-4, shown in FIG. 1; and,

FIG. 5 is an exploded perspective view of the cylindrical evaporative air filter, the water pump, and the water distribution system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning now to the drawings, the portable, self-contained, evaporative air cooler 11 of the present invention comprises an elongated, vertically oriented cylindrical canister 12 and a cooler sub-assembly 13. Canister 12 includes a sidewall 14, preferably right-circular cylindrical in configuration. This configuration is preferred, as it has a compact “footprint”, and uses a relatively small amount of floor space. However, the particular configuration is not critical, and square, pentagonal, hexagonal, or other geometric shapes for the cross-section configuration of canister 12, would work satisfactorily as well. Because it is used in a humid environment, it may be desirable to manufacture canister 12 from a plastic or fiberglass material, for longevity and durability. The use of molded or formed material for canister 12 also lends itself to waterproofing and easy fabrication.

As shown in the drawings, canister 12 has a lower end 16, an upper end 17, and a median portion 18 extending between the upper and lower ends. Lower end 16 includes water storage means in the form of a watertight basin 19, capable of containing several gallons, or more, of water. Watertight basin 19 may be welded, sealed, or otherwise affixed to the bottom portion of sidewall 14. Alternatively, watertight basin 19 may be integrally molded or formed as part of canister 12, when the canister is manufactured. Basin 19 also includes a lower floor 21. The outer side of floor 21 may rest directly on the floor, or it may be supported in spaced relation from the floor by casters or a rolling platform (not shown). It should be pointed out that other water storage means may be substituted for basin 19, such as a separate tank or reservoir within canister 12. Such a tank could be ring-like in configuration, and positioned at any convenient location within canister 12.

The upper end 17 of the canister includes an open top 22, provided with an exhaust duct cutout 23 in the sidewall 14. Open top 22 and exhaust duct cutout 23 both provide conforming and supporting structure to accommodate cooler sub-assembly 13, in a manner to be discussed more fully below.

Median portion 18 of canister 12 includes at least one air inlet 24 in sidewall 14. Air inlet 24 is generally elongated and rectangular in configuration, as shown in FIG. 1. It is preferred that two air inlets be employed, both to reduce incoming air friction and to maximize the exposure of incoming air to working components of the cooler sub-assembly 13. Air inlets 24 include perforated grills 26, to allow the passage of air into the contained volume of canister 12, while limiting physical access therein for reasons of safety.

A water fill fixture 27 is also provided, including an opening 28 in a region of sidewall 14 above an upper water level 29 in the watertight basin 19. Conveniently, water fill fixture 27 comprises an outwardly and upwardly directed curved lip 31, having an upper edge 32 arranged in spaced relation from sidewall 14 and a lower edge 33 attached to sidewall 14. Water fill fixture 27 allows the user to fill and refill the air cooler 11 during the day, as necessary. Fixture 27 also provides a convenient means to empty all water from the basin 19 at the end of the day, or when the cooler 11 needs to be moved to a different location.

Cooler sub-assembly 13 comprises a fan assembly 34 including a fan housing 36, a electric fan motor 37 having a rotary output shaft 38, and a fan impeller 39 attached to output shaft 38. Fan motor 37 and the fan impeller 39 are located within fan housing 36. Fan housing 36 further includes a lower air inlet port 41 adjacent the suction side of fan impeller 39. Housing 36 also includes an air exhaust duct 42, adjacent the output side of the fan impeller 39. Air exhaust duct 42 includes a right-angle or 90° turn, conveniently redirecting outputted air horizontally, in a direction generally tangential to sidewall 14. Other arrangements may be used, such as a straight exhaust duct, or an exhaust duct fitted with a rotatable head to direct air in a selected direction. It should be noted that when cooler sub-assembly 13 is lowered onto canister 12, air inlet port 41 is located within and surrounded by open top 22 and a portion of exhaust duct 42 is located within and surrounded by exhaust duct cutout 23. The remaining portion of exhaust duct 42 extends exteriorly from canister 12, as shown in FIG. 1. In this manner, the cooler sub-assembly 13 is both supported by canister 12 and forms a substantially air-tight seal therewith.

Cooler sub-assembly 13 also includes an evaporative air filter 43. Air filter 43 is elongated and right-circular cylindrical in configuration, generally reflecting the configuration of canister 12. However, air filter 43 is sized to fit within the confined volume of canister 12, in spaced relation from the inner side of sidewall 14. Air filter 43 has an upper end 44 attached to and extending around air inlet port 41. Springs 46, or other convenient attachment means, extend between filter 43 and fan housing 36 to secure the filter 43 in place. The remaining portion of filter 43 extends vertically and downwardly from the air inlet port into the lower interior volume of canister 12. Air filter 43 includes an air permeable element 47 and a foraminous support frame 48. Element 47 is preferably made from a foam or fiberglass material, and support frame 48 may be made from chicken wire, fencing material or another substantially rigid structure capable of maintaining element 47 in the desired configuration and allowing air to pass freely through it.

Lastly, cooler sub-assembly 13 includes an electric submersible water pump 49, located underwater and resting on the floor 21 of basin 19. A water distribution system 51 is also provided, to deliver water to the upper end 44 of the evaporative air filter 43. Water distribution system 51 comprises a vertical water supply line 52 and a circular distribution line 53. Water supply line 52 has a lower end 54 connected to an output fitting 56 on water pump 49, and has an upper end 57 connected to a T-fitting 58, which in turn is connected to circular distribution line 53. Distribution line 53 is positioned around upper end 44 of air filter 43 and includes a plurality of apertures 59 for the passage and delivery of water onto element 47 to maintain it in a saturated condition.

Pump electrical power line 61 is interconnected to cooler switch 62 on the upper side of fan housing 36. When switch 62 is actuated, main electrical power line 63 provides electrical power both to fan motor 37 and to water pump 49. Warm and relatively dry air, represented by horizontal incoming air current 64, is drawn into and through air filter 43. Because element 47 is saturated with water, the incoming air is both cooled and humidified. Thus conditioned, the air is drawn upwardly, as represented by the vertical air current 65. Passing then through the fan impeller 39, the cooled and humidified air is redirected as horizontal outgoing air current 66. Exiting through exhaust duct 42, the conditioned air enters the room to provide cooling. 

1. A portable, self-contained, evaporative air cooler, comprising: a. an elongated, vertically oriented, cylindrical canister having a sidewall, said canister further having a lower end, an upper end, and a median portion therebetween, said lower end including a watertight basin, said upper end having an open top and including an exhaust duct cutout in said sidewall, and said median portion including at least one air inlet in said sidewall; b. a fan assembly including a fan housing, a fan motor having a rotary output shaft, and a fan impeller attached to said output shaft, said fan motor and said fan impeller being located within said fan housing, said fan housing further having a lower air inlet port adjacent a suction side of said impeller and an air exhaust duct adjacent an output side of said impeller, said air inlet port being located within and surrounded by said open top, and a portion of said exhaust duct being located within and surrounded by said exhaust duct cutout; c. an evaporative air filter, said air filter being elongated and cylindrical in configuration, and having an upper end attached to said air inlet port and extending vertically and downwardly therefrom; and, d. a water pump, said water pump being located in said basin and including a water distribution system, said distribution system delivering water to said upper end of said evaporative air filter.
 2. An evaporative air cooler as in claim 1 in which said rotary output shaft is vertical in orientation, and in which said impeller is centrifugal in design, drawing air vertically and upwardly through said air inlet port and discharging air horizontally through said air exhaust duct.
 3. An evaporative air cooler as in claim 1 in which said evaporative air filter includes an air permeable element and a foraminous support frame, said support frame being right-circular cylindrical in configuration.
 4. An evaporative air cooler as in claim 1 in which said air exhaust duct includes a right-angle turn outside said sidewall of said canister.
 5. An evaporative air cooler as in claim 1 further including a water fill fixture including an opening in a region of said sidewall above an upper water level in said watertight basin.
 6. An evaporative air cooler as in claim 5 in which said fixture comprises an outwardly and upwardly directed lip with an upper edge in spaced relation from said sidewall and a lower edge attached to said sidewall.
 7. An evaporative cooler as in claim 1 in which said water distribution system comprises a vertical water supply line and a circular distribution line, said water supply line having a lower end connected to an output fitting on said water pump, and having an upper end connected to said distribution line, said distribution line being positioned around said upper end of said evaporative air filter and including a plurality of apertures for the passage of water therethrough.
 8. An evaporative cooler as in claim 1 further including at least two air inlets in said sidewall, said air inlets being provided with perforated grills.
 9. A portable, self-contained, evaporative air cooler, comprising: a. an elongated, vertically oriented, cylindrical canister having a sidewall, said canister further having a lower end, an upper end, and a median portion therebetween, said upper end having an open top and said median portion including at least one air inlet in said sidewall, b. water storage means within said canister; c. a fan assembly including a fan housing, a fan motor having a rotary output shaft, and a fan impeller attached to said output shaft, said fan motor and said fan impeller being located within said fan housing, said fan housing further having a lower air inlet port adjacent a suction side of said impeller and an air exhaust duct adjacent an output side of said impeller, said air inlet port being located within and surrounded by said open top; d. an evaporative air filter, said air filter being elongated and cylindrical in configuration, and having an upper end attached to said air inlet port and extending vertically and downwardly therefrom; and, e. a water pump, said water pump having a water input fitting in communication with said water storage means and a water output fitting in communication with a water distribution system, said distribution system delivering water to said upper end of said evaporative air filter.
 10. An evaporative air cooler as in claim 9 in which said rotary output shaft is vertical in orientation, and in which said impeller is centrifugal in design, drawing air vertically and upwardly through said air inlet port and discharging air horizontally through said air exhaust duct.
 11. An evaporative air cooler as in claim 9 in which said evaporative air filter includes an air permeable element and a foraminous support frame, said support frame being right-circular cylindrical in configuration.
 12. An evaporative air cooler as in claim 9 in which said air exhaust duct includes a right-angle turn outside said sidewall of said canister.
 13. An evaporative air cooler as in claim 1 further including a water fill fixture outside said sidewall of said canister, said water fill fixture passing through said sidewall and being in communication with said water storage means.
 14. An evaporative air cooler as in claim 13 in which said fixture comprises an outwardly and upwardly directed lip with an upper edge in spaced relation from said sidewall and a lower edge attached to said sidewall.
 15. An evaporative cooler as in claim 9 in which said water distribution system comprises a vertical water supply line and a circular distribution line, said water supply line having a lower end connected to an output fitting on said water pump, and having an upper end connected to said distribution line, said distribution line being positioned around said upper end of said evaporative air filter and including a plurality of apertures for the passage of water therethrough.
 16. An evaporative cooler as in claim 9 further including at least two air inlets in said sidewall, said air inlets being provided with perforated grills.
 17. A portable, self-contained, evaporative air cooler, comprising: a. an elongated, vertically oriented, cylindrical canister having a sidewall, said canister further having a lower end, an upper end, and a median portion therebetween, said lower end including a watertight basin, said upper end having an open top and said median portion including at least one air inlet in said sidewall; b. a fan means having an air inlet port and an air exhaust duct, said air inlet port being located within and surrounded by said open top; c. an evaporative air filter, said air filter being elongated and cylindrical in configuration, and having an upper end attached to said air inlet port and extending vertically and downwardly therefrom; and, d. a water pump, said water pump being located in said basin and including a water distribution system, said distribution system delivering water to said upper end of said evaporative air filter.
 18. An evaporative air cooler as in claim 17 in which said evaporative air filter includes an air permeable element and a foraminous support frame, said support frame being right-circular cylindrical in configuration.
 19. An evaporative air cooler as in claim 17 further including a water fill fixture including an opening in a region of said sidewall above an upper water level in said watertight basin.
 20. An evaporative air cooler as in claim 19 in which said fixture comprises an outwardly and upwardly directed lip with an upper edge in spaced relation from said sidewall and a lower edge attached to said sidewall. 